Two-piece key assembly

ABSTRACT

A key assembly is disclosed. The key assembly may have a blade with a head portion, a shank, and a transition region connecting the head portion to the shank. The key assembly may also have a head configured to receive the blade. The head may have a shoulder located at the transition region to limit engagement of the head with the blade, and at least one tang located at an end of the head opposite the shoulder. The at least one tang may be configured to engage a recess located within a side of the head portion and inhibit removal of the head from the blade.

RELATED APPLICATIONS

This application is based on and claims the benefit of priority fromU.S. Provisional Application No. 61/866,603 entitled MODULAR KEYDUPLICATION SYSTEM USING COMMON KEY BLANKS that was filed on Aug. 16,2013 and from U.S. Provisional Application No. 61/904,810 entitled KEYASSEMBLY AND DUPLICATION MACHINE that was filed on Nov. 15, 2013, thecontents of both of which are expressly incorporated herein byreference.

TECHNICAL FIELD

The present disclosure is directed to a key assembly and, moreparticularly, to a two-piece key assembly.

BACKGROUND

A master key can be duplicated in any number of different ways, bymeasuring a profile of the master key and duplicating that profilewithin a key blank. The key blank generally has a size and shape largerthan the master key, so that the key blank can be machined (e.g., cutand/or milled down) to function like the master key. In order to reducean amount of key blank inventory that a locksmith must keep on hand forduplication purposes, common or universal key blanks may be utilized.

An exemplary key for use in duplication operations is disclosed in U.S.Patent Application Publication No. 2004/0148988 of Taylor that publishedon Aug. 5, 2004 (“the '988 publication”). Specifically, the '988publication discloses a metallic blade on which serrations are to beformed, and a key head made of jewelry and having a receiving slot forreceiving an inserting portion of the key blade. The key head is fixedto the blade by way of friction, glue, epoxy, or welding, and includesinsignia surfaces for decorative design.

Although the key of the '988 publication may be decorative and provide acustomer with certain options, it may still be less than optimal. Inparticular, the head may be expensive to fabricate, difficult to connectto the blade, and inhibit interchangeability of heads. Further, theblade may not be conducive to an automated fabrication process.

The disclosed key assembly is directed to overcoming one or more of theproblems set forth above and/or other problems of the prior art.

SUMMARY

In one aspect, the present disclosure is directed to a key assembly. Thekey assembly may include a blade having a head portion, a shank, and atransition region connecting the head portion to the shank. The keyassembly may also include a head configured to receive the blade. Thehead may have a shoulder located at the transition region to limitengagement of the head with the blade, and at least one tang located atan end of the head opposite the shoulder. The at least one tang may beconfigured to engage the head portion and inhibit removal of the headfrom the blade.

In another aspect, the present disclosure is directed to a blade for akey assembly. The blade may include a shank with a proximal end and adistal end, a head portion having a base end and a tip end, and atransition region connecting the base end of the head portion to theproximal end of the shank. The blade may also include at least oneshoulder located between the base end of the head and the tip end, andat least one recess located between the at least one shoulder and thetip end. The at least one recess may have ends oriented at obliqueangles relative to sides of the head portion.

In another aspect, the present disclosure is directed to a head for akey assembly. The head may include at least one primary interiorsurface, and at least one side surface substantially perpendicular tothe primary interior surface. The head may also include at least onetang connected to the at least one side surface and configured to engagea blade recess of the key assembly.

In another aspect, the present disclosure is directed to a key blankinventory system. The key blank inventory system may include a pluralityof different key blades, and a plurality of different key heads. Each ofthe plurality of different key heads may be configured to receive eachof the plurality of different key blades.

In another aspect, the present disclosure is directed to another keyblank inventory system. This key blank inventory system may include aplurality of key blades, a first plurality of key heads configured topermanently connect with the plurality of key blades, and a secondplurality of key heads configured to removably connect with theplurality of key blades. Each of the second plurality of key heads mayhave a transponder chip.

In another aspect, the present disclosure is directed to another keyblank inventory system. This key blank inventory system may include akey blade, and a key head configured to receive the key blade in asingle direction and lock onto the key blade in multiple orientations.

In another aspect, the present disclosure is directed to another keyassembly. This key assembly may include a key blade, and a key headconfigured to be pushed by hand over a head portion of the key blade.The key head may resist separation from the key blade through onlymechanical interlocking of the key head with the key blade.

In another aspect, the present disclosure is directed to a method ofassembling a key. The method may include inserting a key blade headportion-first into a separate key head component, and deforming theseparate key head component during insertion. The method may alsoinclude allowing the separate key head component to return to a nearoriginal shape after insertion of the key blade to inhibit removal ofthe key blade.

In another aspect, the present disclosure is directed to an inventorysystem of consumer-oriented hand-held components. The inventory systemmay include a plurality of different key blades, and a plurality ofdifferent handheld non-key related utensils. The inventory system mayalso include a plurality of different heads, each being permanentlyconnectable with each of the plurality of different key blades and witheach of the plurality of different handheld non-key related utensils.

In another aspect, the present disclosure is directed to an inventorysystem. The inventory system may include a key blade configured to havenotches formed therein at a point of purchase, and a key head configuredto be manually assembled without tooling to the key blade at the pointof purchase.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C are front view and end view illustrations of three differentexemplary disclosed key assemblies;

FIGS. 2A-2C are front and side view illustrations of an exemplarydisclosed key blade that forms a portion of the key assembly of FIG. 1A;

FIGS. 3A-3C are front, back, and side view illustrations of an exemplarydisclosed head that receives the key blade of FIGS. 2A-2C to form thekey assembly of FIG. 1A;

FIG. 4 is a front view illustration of another exemplary disclosed keyassembly; and

FIG. 5 is a top view illustration of an exemplary disclosed inventorysystem of consumer-oriented handheld components.

DETAILED DESCRIPTION

FIGS. 1A-1C illustrate three different exemplary key assemblies 10 a, 10b, and 10 c, which will collectively be referred to as key assembly 10in this disclosure. Each key assembly 10 may be used as a means forgaining access to a variety of different secure applications, forexample to automotive applications (e.g., door and ignition locks), toresidential applications (e.g., dead bolt and handle locks), and tocommercial applications (e.g., equipment and facility locks). Each keyassembly 10 may generally include a blade 12, and a head 14 that isconnected to blade 12. As shown in FIGS. 1A-1C, head 14 is a separatecomponent or subassembly of components that is connected to blade 12before or after formation of desired features within blade 12. It iscontemplated that head 14 may be fixedly or removably connected to blade12, as desired. When head 14 is connected to blade 12, one end or bothends (both ends shown in FIGS. 1A-1C) of blade 12 may protrude adistance from head 14. Head 14 may serve as a handle through which auser generates torque within blade 12, causing an associated lock toturn and open or close.

As shown in FIGS. 1A-1C, each of key assemblies 10 a-10 c may be adifferent type of key assembly. In particular, key assembly 10 a mayhave a single edge-cut form (shown in FIG. 1A); key assembly 10 b mayhave a dual edge-cut form (shown in FIG. 1B); and key assembly 10 c mayhave a milled form (shown in FIG. 1C). In general, key assembly 10 a,having the single edge-cut form, may include blade 12 with a singlerelatively thinner lengthwise outer edge 46 that is configured to benotched in a particular pattern (shown in phantom lines as notches 49)corresponding to the lock intended to receive blade 12, and a singlerelatively thicker opposing outer edge 48 that does not include notches49. Key assembly 10 b with the dual edge-cut form may have two opposingouter edges 46 that are notched and thinner relative to a thicker centersection 50. Center sections 50 within blades 12 of both the single anddual edge-cut key assemblies 10 a, 10 b may include one or more channels52 formed therein, such that an endwise cross-section of each assemblyhas a general zigzag shape. Key assembly 10 c, having the milled form,may include relatively thicker square outer edges 51, with a planarcenter section 50 of about the same thickness (i.e., a cross-section ofa milled form may be generally rectangular). Center section 50 of themilled key assembly 10 c generally has an internal pattern of notches 49that is milled within center section 50 and located away from edges 51,the pattern being variable and corresponding to the lock intended toreceive blade 12.

An exemplary blade 12 for single edge-cut key assembly 10 a is shown inFIGS. 2A-2C. As shown in these figures, blade 12 may include a headportion 16, and a shank 18 that is integrally formed with head portion16. Head portion 16 may join shank 18 at a transition region 20. In thedisclosed embodiment, blade 12 is formed from aluminum, brass, bronze,or another metal alloy through a stamping process and may or may not bepainted or otherwise plated with a colored film. It is contemplated,however, that another material and/or process may be utilized to formblade 12, if desired.

Head portion 16 of blade 12 may have geometry designed to interact withcorresponding geometry of head 14 (referring to FIGS. 1A-1C). Inparticular, as shown in FIGS. 2A-2C, head portion 16 may be generallyplate-like, having a substantially uniform thickness t along its lengthl from a square shaped base end 22 within transition region 20 to arounded tip end 24. In the disclosed embodiment, thickness t betweenopposing primary surfaces 26, 28 may be about 0.075-0.1 inches (e.g.,about 0.08 inches) and length l may be about 1.25-1.5 inches (e.g.,about 1.33 inches). Head portion 16 may also have a generally uniformwidth w between opposing side surfaces 30, 32 of about 0.4-0.5 inches(e.g., about 0.486 inches). These specific dimensions may be selected toproduce a slip fit of head portion 16 within an internal cavity of head14. Head portion 16 may be engaged on its two primary faces 26, 28 andits two substantially perpendicular side surfaces 30, 32 when slidinglyreceived within head 14.

Each head portion 16 may also have geometry designed to inhibit removalof blade 12 from head 14. In particular, one or more recesses 34 may beformed within side surfaces 30, 32 and configured to receivecorresponding locking features of head 14. Recesses 34 may have opposingends 36, 38 that are angled obliquely outward and configured to engageor provide clearance for the locking features, respectively. It iscontemplated that the angular orientation of ends 36, 38 may be the sameor different, as desired. A pair of shoulders 40 may protrude from sidesurfaces 30, 32, at a common location between recesses 34 and base end22. Shoulders 40 may be located a particular distance away from recesses34 and function as end stops for head 14 during assembly (see FIGS.1A-1C). Shoulders 40 may also inhibit head 14 from being installedincorrectly (i.e., upside down) onto key blade 12. In some embodiments,a shape, size, and/or position of shoulders 40 may also be used todetermine an identity of blade 12 and/or to locate blade 12 during acutting process, if desired.

In some embodiments, an accessory engagement feature (e.g., an eyelet)41 may be formed at tip end 24 and configured to engage a separatelypurchased accessory (e.g., a key ring). In these same embodiments,eyelet 41 may function as an additional or alternative locating featureused during cutting of shank 18, if desired. For example, a center ofeyelet 41 may be precisely located a distance d from shoulders 40 and/orfrom base end 22 (e.g., about 0.7-0.8 inches from shoulders 40).Although tip end 24 is shown as having a generally curved outerperiphery that enhances rigidity of head portion 16, it is contemplatedthat head portion 16 could alternatively have an angled or square outerperiphery if desired.

One or more identification indices may be formed within or otherwiseapplied to head portion 16 and used to identify blade 12 as a particularone of a plurality of known types of key blades. In the disclosedexample, two indices are shown, including a first index 42 and a secondindex 44. Indices 42, 44 may take any form known in the art for relayinginformation regarding the identity of blade 12, and indices 42, 44 maybe the same or different. For example, index 42 may be a type of indexreadable by a key duplication technician and still visible after head 14is assembled to blade 12. In the same example, index 44 may be a type ofindex that is machine readable and visible only before and/or duringcutting of shank 18 (i.e., index 44 may be located at a center of wherehead 14 is to be installed). Examples of different types of indicesinclude alpha-numeric symbols (see index 42 in FIGS. 1A-2A), bar codes(see index 44 in FIGS. 1A-2A), data matrices, QR codes, etc. Althoughthe depicted blade 12 includes indices 42, 44 located at only one side(i.e. only at primary surface 26), it is contemplated that indices 42,44 could be located at both sides and/or at other positions, if desired.

In some embodiments, shank 18 may have a thickness different than athickness of head portion 16. In these embodiments, a step 54 (shownonly in FIG. 2C) may be located at transition region 20, and transitionregion 20 may extend from shoulders 40 to base end 22. This step may bethe result of a first type of blade 12 having either its head portion 16or its shank 18 milled thinner after formation through the stampingprocess discussed above. That is, all blades 12 may need to have acommon thickness at head portion 16 to properly receive a common head14, but blades 12 of different key types may have shanks 18 with athickness that is the same or different (i.e., thicker or thinner). Insituations where shank 18 is required to be thicker than the common headportion thickness, all of blade 12 may be stamped from a thickermaterial and then head portion 16 may be machined thinner to the commonthickness. In contrast, in situations where shank 18 is required to bethinner than the common head portion thickness, all of blade 12 may bestamped from material having the common head thickness, but then shank18 may be machined thinner. In other words, after stamping of differentblades 12, some blades (e.g., the most commonly used blades 12) may beready for notching (i.e., cutting and/or milling) without furtherchange, while other blades 12 may need to have their head portions 16 ortheir shanks 18 machined to be thinner, depending on the requirements ofthe corresponding locks. But in all situations, head portions 16 mayhave the same thickness when formation of blade 12 is complete. It iscontemplated that, in some applications, a length of blade 12 may alsoneed to be shortened during the duplication process.

Head 14, in the embodiments of FIGS. 1A-1C, is a subassembly of twosubstantially identical head components 14 a oriented in opposition toeach other. As shown in FIGS. 3A-3C, each head component 14 a mayinclude a primary interior surface 56 and a side surface 58 that issubstantially perpendicular to primary interior surface 56. When twohead components 14 a are placed together in opposite orientationrelative to each other (i.e., with primary interior surfaces 56 facingeach other and side surfaces 58 facing each other), a cavity 60 (shownonly in FIG. 3C) may be formed that is configured to slidingly receivehead portion 16 of blade 12. One or more connecting features may beassociated with each head component 14 a and configured to engagecorresponding features in the mating head component 14 a, therebymaintaining connection between head components 14 a. For example, one ormore pins 62 may protrude at one edge of primary interior surface 56 andbe received within one or more corresponding bores 64 located at anopposing edge of primary interior surface 56. Accordingly, when two headcomponents 14 a are pressed together, four pins 62 (one located at eachcorner of primary interior surface 56) may enter four bores 64. In someembodiments, removal of pins 62 from bores 64 may be inhibited tothereby prevent unintended disassembly of head 14. Pins 62 may beinhibited from removable by way of an interference fit, an adhesive, oranother mechanism known in the art.

In other embodiments, head 14 is a single-piece integral componenthaving many features in common with the two head components 14 adescribed above. In these embodiments, the single-piece head 14 includestwo primary interior surfaces 56 and two side surface 58 that aresubstantially perpendicular to primary interior surfaces 56 to formcavity 60. In this arrangement, no subassembly is required and nocorresponding connecting features (i.e., pins 62 or bores 64) are formedwithin head 14.

In either of the two-piece or single-piece embodiments of head 14, afirst end 66 of head 14 may be pushed by hand (i.e., without the use oftooling) over tip end 24 of blade 12 and pushed toward shank 18. Twosteps 68 may be formed at first end 66 (e.g., one step 68 within eachhead component 14 a) and configured to engage shoulder 40 of blade 12(see FIGS. 1A-1C), thereby positioning head 14 at a desired locationalong blade 12. Two tangs 70 may be located at a second end 72 of head14 (e.g., one tang 70 within each head component 14 a) and configured todeflect out of the way (i.e., deform) of blade 12 (i.e., out of cavity60) during insertion and then return to a near original position (shownin FIGS. 1A-1C) within recesses 34 of blade 12, thereby mechanicallyinterring with and thereby inhibiting removal of head 14 from blade 12.Each tang 70 may have a proximal end near a center of head 14, and adistal end that protrudes toward second end 72 at an inward angle. Theangle of recess end 36 (referring to FIG. 2A) may allow for a secureseating of tang 70 without binding (see FIGS. 1A-1C), while the angle ofrecess end 38 may provide clearance for the inward intrusion of tang 70.In this configuration, the only way that head 14 could be removed fromblade 12 would be to cause buckling or other physical alterations oftangs 70, which would require significant force. In some embodiments,there may not be sufficient space within cavity 60 for tangs 70 tobuckle, making removal of head 14 even more difficult, if notimpossible, without destruction of head 14.

In the disclosed embodiment, head 14 is injection molded from a plasticmaterial. Accordingly, head 14 (e.g., each head component 14 a) may havefeatures that facilitate this fabrication method and/or material. Forexample, a pocket 74 may be formed at a location between bores 64 (ifbores 64 are present). Pocket 74 may help to keep all walls of head 14at about the same thickness, thereby reducing the formation of voids oruneven surfaces during molding. It is contemplated that pocket 74 may beomitted, if desired. It is also contemplated that head 14 could befabricated from other materials and/or through other processes.

Head 14 may also include features that improve use of key assembly 10.For example, head 14 may include one or more friction-enhancingfeatures, such as raised bumps 76 at an outer surface 78. These featuresmay help to reduce the likelihood of a customer's hand slipping duringuse of key assembly 10. Head 14 may also have a smooth, roundedperiphery that helps to reduce snagging. Head 14 may be fabricated in avariety of colors and/or shapes.

There may be times when removal head 14 from key blade 12 withoutcausing damage to head 14 is desirable. For example, when notches 49have not been properly fabricated within key blade 12 and/or when damageto key blade 12 has occurred, it may be desirable to remove head 14 andreuse head 14 with another key blade. This may be particularly true whenhead 14 is a transponder head, which is generally more expensive than astandard or non-transponder head. FIG. 4 illustrates an exemplaryembodiment of key assembly 10 (e.g., 10 c) having a transponder head 80connected to key blade 12. In this embodiment, transponder head 80 is atwo-piece component having a transponder chip 82 removably or fixedlycontained inside. Specifically, transponder head 80 may include a lowercomponent 84 having an opening 86 to receive head portion 16 of keyblade 12 (shank-first), and an upper component on 88 configured to matewith lower component 88 and thereby inhibit removal of key blade 12.Transponder chip 82 may be located within lower or upper components 84,88, as desired. A fastener (e.g., a screw, a clip, etc.) 90 may connectupper component 88 to lower component 84. It should be noted that otherremovable head designs having transponder chip 82 may be utilizedtogether with key blade 12.

FIG. 5 shows alternative uses of head 14 within an inventory system ofconsumer-oriented handheld components. In particular it may beprofitable to design head 14 to receive items other than just blade 12.For example, hand-held consumer-oriented items or utensils, such as abottle opener 301, a money clip 302, a portable media drive 304, a pursehook 306, a key ring 308, and a refrigerator magnet 310, may befabricated with geometry similar to the geometry of head portion 16 ofkey blade 12, such that these items can accept and lock together withhead 14 in the same manner described above. It is contemplated thatthese items may be purchased along with head 14 and blade 12 at a pointof sale. In one embodiment, head 14 may even be customized the point ofsale, for example head 14 may be decorative in nature and printed on,etched, milled, applied with an adhesive backing, etc. to bear a desiredshape, symbol, logo, and/or image.

INDUSTRIAL APPLICABILITY

The disclosed key assembly may be utilized for duplicating a singleedge-cut key, a dual edge-cut key, and a side-milled key. The disclosedkey assembly may be easy to use and facilitate accurate duplication witha reduced number of miscuts. An exemplary duplication process using thedisclosed key assembly will now be described in detail.

To begin the fabrication process (i.e., the process of creating notches49 within key blade 12), a customer or sales associate must identify themaster key to be duplicated. This identification may be completedmanually or automatically, and include a type of lock to which the keycorresponds; a year, make, or model of the corresponding application; aknown or measured notch pattern; and/or a type, size, shape, or model ofthe corresponding key blank. Based on this information, a key blade 12that should be used in the fabrication process may be selected. Thisselection may be performed manually or automatically, as desired.

Once the appropriate key blade 12 corresponding to the master key hasbeen selected, the key blade 12 may be retrieved from inventory and cutto have notches 49 that correspond with the notch pattern of the masterkey. In some instances, the identity of the retrieved key blade 12 maybe confirmed before cutting may begin. And this confirmation may be donein several different ways. In one application, a store sales associate(or the end user or customer themselves) may compare index 42 of theretrieved key blade 12 with the intended index 42 of the selected keyblade 12. For example, the key blade 12 selected based on theidentification information of the master key may be a key type #66. Inthis example, the store sales associate may ensure that index 42 of theretrieved key blade 12 has #66 stamped therein. In another application,identity confirmation of the retrieved key blade 12 may be performedautomatically by a duplication machine (not shown). For example, theduplication machine may detect index 44 (e.g., the barcode printed on orotherwise applied to head portion 16 as a decal, a tag, a label,chemical etching, a sleeve, etc.), identify the retrieved key blade 12based on stored information corresponding to the detected index 44, andcompare the identity with the intended identity of the selected keyblade 12.

After the identity of the retrieved key blade 12 has been confirmed, thefabrication of notches 49 may begin. In manual processes, the retrievedkey blade 12 may be manually mounted within a clamp and then positionedto engage a cutting wheel and/or a milling head. And during thisprocess, key blade 12 may be manually moved relative to the cuttingwheel and/or milling head in such a way that the desired notch patternis created within blade 12. This may be performed, for example, using atracing apparatus in association with a master key. It is alsocontemplated that the cutting wheel and/or milling head couldalternatively be held stationary, and key blade 12 moved to cut thenotch pattern, if desired.

In an automated cutting process, the retrieved key blade 12 may beinserted into a cutting module of a duplication machine. In someinstances, only shank 18 may need to be inserted into the cuttingmodule. In other instances, all of key blade 12 may need to be inserted.Regardless of the configuration of the particular cutting module, index44 may be used to facilitate the cutting process. For example, ascanner, camera, or other detection device may be located to detect thebarcode of index 44 once key blade 12 (or only shank 18) has beeninserted into the cutting module. In some instances, this detection maybe part of the identity confirmation step described above. In otherinstances, this detection may be an additional step.

Detection of index 44 within the cutting module may be used to confirmthat key blade 12 has been inserted properly into the cutting module.For example, the barcode of index 44 may be located on only one side ofkey blade 12. And when index 44 is not detected upon insertion of keyblade 12, it may be concluded that key blade 12 is not insertedproperly. Improper insertion may include not fully inserting key blade12 or inserting key blade 12 upside-down. When this occurs, key blade 12may need to be pushed in further or pulled out and turned over.

The information encoded within index 44 may be used within an automatedkey fabrication machine to cut the desired pattern of notches 49. Forexample, the information encoded within the barcode of index 44 mayinclude the identity of key blade 12, geometry of key blade 12 (e.g.,size, shape, material, etc.), and/or clamping requirements (location,orientation, position, force, etc.) of key blade 12. This informationmay be deciphered by the cutting module of the automated fabricationmachine, and used to set up the machine in such a way that allows propercutting of key blade 12.

Before, during, and after the cutting process has been completed, asales transaction associated with the cutting process may be completed.This sales transaction may include using the barcode of index 44 todetermine the key blade 12 used for the process, a type of cuttingprocess involved (e.g., cutting or milling), a corresponding reductionin key blade inventory, and/or a cost of the transaction. For example,the sales associate may scan the bar code on head portion 16, and chargethe customer a corresponding amount at a point of sale. At this sametime, the customer may also choose and pay for a corresponding head 14.Thereafter, the sales associate or the customer may assemble head 14 tokey blade 12, by pushing end 66 of head 14 over tip end 24 of headportion 16. Head 14 may be assembled to key blade 12 in only a singledirection (i.e., head-first) and in two different orientations (e.g., afront orientation and a back orientation) that are 180° rotated fromeach other about a length direction of key blade 12.

The disclosed key assembly may be inexpensive to fabricate, simple toassembly, and provide for head/blade interchangeability. Specifically,with key blades 12 being stamped and head 14 being molded, the cost offabrication may be reduced. In addition, a common or universal key blade12 may be used to make many different types, styles, and sizes of keys.And likewise, head 14 may be used on many different key blades 12. Thiscommonality may help to keep the number of different key blades 12 andheads 14 low and the volume high, which further reduces component cost.Further, because head 14 can be connected to key blade 12 simply bypushing head 14 over head portion 16, the time and effort associatedwith assembly may be low. And the low cost nature and commonality ofhead 14 and the ease of assembly may allow for the customer to choosefrom many different styles, configurations, and/or colors of heads to beused with any key blade 12.

In addition, because head 14 may be universal and can be connected toany key blade 12, the customer may be provided with greater variety.Specifically, a greater assortment of different head designs may beprovided with reduced inventory, as each different head 14 can fit anykey blade 12. Instead of having to make dozens of different key headseach having the same logo or design that fit dozens of different keyblades, one head may be created that fits all key blades 12; and eachhead 14 may have a different logo. Thus a greater variety of heads 14may be created and stocked in inventory for use by the customer.

Further, by having two different subsets of heads, one removable and theother non-removable, a cost of an associated key blank inventory systemmay be small. Specifically, heads 14 may be relatively cheaper thanheads 80, because heads 14 do not include transponders 82. Accordingly,heads 14 may be cheap enough to discard, if necessary due to fabricationerror or key blade damage. For this reason, heads 14 do not need to havegeometry that allows heads 14 to be removable and reusable. Thisgeometry may increase a cost of key assembly 10 and, accordingly, mayonly be useful with the more expensive key assemblies 10 havingtransponders. Thus, by having two sets of key assemblies with twodifferent types of heads, the cost of the inventory system may be low.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the disclosed key assembly.Other embodiments will be apparent to those skilled in the art fromconsideration of the specification and practice of the disclosed keyassembly. It is intended that the specification and examples beconsidered as exemplary only, with a true scope being indicated by thefollowing claims and their equivalents.

What is claimed is:
 1. A key assembly, comprising: a blade having: ahead portion; a shank; and a transition region connecting the headportion to the shank; and a head configured to receive the blade, thehead having: a step located at the transition region when the head isassembled to the blade to limit engagement of the head with the blade;and at least one tang integrally formed with the head and located at anend of the head opposite the step, the at least one tang configured toengage the head portion and inhibit removal of the head from the blade.2. The key assembly of claim 1, wherein the step is recessed inside thehead, and the key assembly further includes at least one shoulder thatprotrudes from a side surface of the head portion to engage the step. 3.The key assembly of claim 2, wherein: the at least one shoulder includestwo shoulders located at opposing sides of the head portion; and the atleast one tang includes two tangs that are configured to engage recesseslocated at opposing sides of the head portion.
 4. The key assembly ofclaim 3, wherein the recesses have flat ends oriented at oblique anglesrelative to sides of the head portion.
 5. The key assembly of claim 1,wherein the head portion is rounded at an end opposite the shank thatprotrudes from the head, and includes an eyelet formed therein.
 6. Thekey assembly of claim 1, wherein the head portion further includes amachine readable index covered by the head after assembly.
 7. The keyassembly of claim 6, wherein the head portion further includes a humanreadable index visible after assembly of the head to the blade.
 8. Thekey assembly of claim 1, wherein the shank includes: a first edgeconfigured to be notched; and a second edge thicker than and locatedopposite the first edge.
 9. The key assembly of claim 1, wherein theshank includes: a first edge configured to be notched; a second edgelocated opposite the first edge and configured to be notched; and acenter that is thicker than the first and second edges.
 10. The keyassembly of claim 1, wherein a cross-section of the shank is rectangularand has a substantially constant thickness along its length.
 11. A bladefor a key assembly, comprising: a shank with a proximal end and a distalend; an integral head portion having a base end and a tip end; atransition region connecting the base end of the head portion to theproximal end of the shank; at least one shoulder located between thebase end of the head portion and the tip end; and at least one recesslocated between the at least one shoulder and the tip end, the at leastone recess having flat end surfaces oriented at oblique angles relativeto sides of the head portion.
 12. The blade of claim 11, wherein the atleast one shoulder protrudes from a side of the head portion.
 13. Theblade of claim 11, wherein the head portion is rounded at an endopposite the shank and includes an eyelet formed therein.
 14. A head fora key assembly, comprising: at least one primary interior surface; atleast one side surface substantially perpendicular to the at least oneprimary interior surface and together with the at least one primarysurface forming an internal cavity configured to receive a blade of thekey assembly via a first end; and at least one tang protruding from theat least one side surface and configured to engage a blade recess of thekey assembly, wherein the at least one tang includes a distal endextending toward a center of the internal cavity, and a stationary baseend located closer to the first end than the distal end.
 15. The head ofclaim 14, further including an internal step located at an end oppositethe at least one tang, the internal step configured to limit anengagement depth of a blade of the key assembly into the head.
 16. Thehead of claim 14, wherein: the at least one primary interior surface andthe at least one side surface are included in a first head component;the first head component further includes: at least one pin located at afirst edge of the at least one primary interior surface; and at leastone bore located at a second edge of the at least one primary interiorsurface opposite the first edge; and the head further includes a secondhead component substantially identical to the first head component andconfigured to engage the first head component in an opposing orientationto create an internal cavity from the at least one primary and at leastone side surface of both the first and second head components.
 17. Thekey assembly of claim 1, wherein the at least one tang includes astationary base end and a distal end configured to engage the headportion of the blade.